Systems and Methods for Increasing Output Current Quality, Output Power, and Reliability of Grid-Interactive Inverters

ABSTRACT

Various enhancements to grid-interactive inverters in accordance with embodiments of the invention are disclosed. One embodiment includes input terminals configured to receive a direct current, output terminals configured to provide an alternating output current to the utility grid, a controller, an output current sensor, and a DC-AC inverter stage comprising a plurality of switches controlled by control signals generated by the controller. In addition, the controller is configured to: generate control signals that cause the switches in the DC-AC inverter stage to switch a direct current in a bidirectional manner; measure the alternating output current; perform frequency decomposition of the output current; and generate control signals that cause the switches in the DC-AC inverter stage to switch current in a way that the magnitude of a plurality of unwanted current components is subtracted from the resulting output current.

CROSS-REFERENCE TO RELATED APPLICATION

The present invention is a continuation of U.S. patent application Ser.No. 16/172,523, entitled “Systems and Methods for Increasing OutputCurrent Quality, Output Power, and Reliability of Grid-InteractiveInverters”, filed Oct. 26, 2018, which is a continuation of U.S. patentapplication Ser. No. 15/614,352, entitled “Systems and Methods forIncreasing Output Current Quality, Output Power, and Reliability ofGrid-Interactive Inverters”, filed Jun. 5, 2017, which is a continuationof U.S. patent application Ser. No. 15/043,240, entitled “Systems andMethods For Increasing Output Current Quality, Output Power, andReliability of Grid-Interactive Inverters,” filed Feb. 12, 2016 andissued on Jul. 4, 2017 as U.S. Pat. No. 9,698,668, which application isa continuation of U.S. patent application Ser. No. 14/329,775, entitled“Systems and Methods for Increasing Output Current Quality, OutputPower, and Reliability of Grid-Interactive Inverters,” filed Jul. 11,2014 and issued on Feb. 16, 2016 as U.S. Pat. No. 9,263,936, whichapplication is a continuation of U.S. patent application Ser. No.13/546,993, entitled “Systems and Methods for Increasing Output CurrentQuality, Output Power, and Reliability of Grid-Interactive Inverters,”filed Jul. 11, 2012 and issued on Jul. 15, 2014 as U.S. Pat. No.8,780,592, which application claims priority under 35 U.S.C. § 119(e) toU.S. Provisional Patent Application Ser. No. 61/506,343 entitled“Isolated Grid-Tied Inverter Architecture with Combined SignalProcessing for Low Current Total Harmonic Distortion,” filed Jul. 11,2011, the disclosures of which are incorporated by reference herein intheir entirety.

FIELD OF THE INVENTION

The present invention relates to grid-interactive inverters and morespecifically to the current quality, power production, and reliabilityof grid-interactive inverters.

BACKGROUND

Alternative energy systems can be classified according to whether theyare stand-alone systems or grid-connected systems. Mostly, a stand-alonesystem is used in off-grid applications with battery storage. In agrid-connected system, excess power can be sold to an electric utilityor “the Grid”, typically in the afternoon hours of the day which happento coincide with peak rate times. When the grid-connected system isgenerating less than the consumed amount of power, the Grid continues tosupplement the power generated by the alternative energy system.

Grid-interactive inverters (commonly referred to as grid-tie inverters)are a type of power inverter that converts direct current (DC) intoalternating current (AC) that is fed to the Grid. Current will flow fromthe inverter to the Grid when the instantaneous voltage supplied at theinverter outputs exceeds the instantaneous grid voltage.

When a photovoltaic module is the source of the direct current, agrid-interactive inverter inverts a relatively low and variable DCvoltage to a relatively high AC voltage that is matched to the Grid. Avariety of grid-interactive inverter structures can be utilized inapplications involving photovoltaic modules including grid-interactiveinverters that are derivatives of a basic H-bridge topology andstructures that are derivatives of a neutral point clamped (NPC)topology. A typical grid-interactive inverter includes a stage thatconverts DC voltage to AC voltage using switches that switch current ina bidirectional manner across the output terminals of thegrid-interactive inverter to provide AC to the Grid. The switches aretypically implemented using transistors, which are controlled usingpulse width modulation (PWM) signals that define the periods of time inwhich individual transistors are ON or OFF. When the switches arecontrolled in an appropriate manner and the voltage drop across theoutput filter is sufficiently large relative to the Grid voltage, thebidirectional flow of current through the output filter results in asinusoidal current at the output of the grid-interactive inverter thatis compatible with the Grid.

In many implementations, the DC voltage received by the grid-interactiveinverter does not exceed the peak voltage of the Grid and so a directDC-AC inversion is not performed. Instead, multiple stages are utilizedwithin the grid-interactive inverter that boost the received DC voltageto a DC voltage exceeding the rectified voltage of the Grid, and invertthe boosted DC voltage to provide AC to the Grid. A common technique forboosting the DC voltage received from a photovoltaic module is toconvert the DC to AC and to utilize an appropriately wound transformerto step the AC voltage up to a higher voltage. The stepped up AC outputcan be full wave rectified to provide a DC voltage to the DC-AC inverterstage that exceeds the peak voltage of the Grid. In manyimplementations, the DC-DC conversion stage utilize switches that switchcurrent in a bidirectional manner through the primary coil of atransformer. The output of the secondary coil can then be full waverectified to accumulate charge on a DC link capacitor. The DC linkcapacitor serves as an energy buffer. The peak current draw on the DClink capacitor by the DC-AC inverter stage typically exceeds the currentprovided to the DC link capacitor by the DC-DC conversion stage.Therefore, the DC link capacitor stores enough charge to meet the peakcurrent draw of the DC-AC inverter stage and enable power to be exportedby the grid-interactive inverter throughout each grid cycle. Theswitching of current through the primary coil of the transformer bytransistors in the manner outlined above can be controlled using PWMcontrol signals. As can readily be appreciated, the AC in a DC-DCconversion stage need not have a frequency and/or phase matched to theGrid. Instead, the frequency and/or phase of the AC can be determinedbased upon the performance of the DC-DC conversion stage.

The PWM control signals that drive the switches in the various stages ofa grid-interactive inverter are typically generated by a controller thatmonitors the Grid voltage and adjusts the switching of the DC-ACinverter stage to produce a current compatible with the Grid. Thepresence of a controller within a grid-interactive inverter can enableother functionality targeted at improving the efficiency and/or poweroutput of the inverter. For example, photovoltaic modules typically havea non-linear output efficiency that can be represented as an I-V curve.The I-V curve provides information concerning the current that theinverter should draw from the photovoltaic module to obtain maximumpower. Maximum power point tracking is a technique involving applicationof a resistive load to control the output current of a photovoltaicmodule and maximize power production.

Micro-inverters are a class of grid-interactive inverter that converts aDC voltage from a single photovoltaic module to an AC voltage. A keyfeature of a micro-inverter is not its small size or power rating, butits ability to perform maximum power point tracking to control on asingle panel. Micro-inverters are commonly used where array sizes aresmall and maximizing performance from every panel is a concern.

Where panels are connected in series, a string inverter can be utilized.A benefit of connecting panels in series in this way is that the DCvoltage provided to the string inverter can be sufficiently high so asto exceed the peak grid voltage. As noted above, a single stage invertercan be utilized when the DC input voltage exceeds the peak grid voltage.Typically, a single stage inverter is more efficient than a multiplestage inverter due to energy losses that occur in DC-DC conversionstages associated with the transformer and switching losses. Stringinverters are typically used with larger arrays of photovoltaic modules.

SUMMARY OF THE INVENTION

Various enhancements to grid-interactive inverters in accordance withembodiments of the invention are disclosed. One embodiment includesinput terminals configured to receive a direct current, output terminalsconfigured to provide an alternating output current to the utility grid,a controller, an output current sensor, and a DC-AC inverter stagecomprising a plurality of switches controlled by control signalsgenerated by the controller. In addition, the controller is configuredto generate control signals that cause the switches in the DC-ACinverter stage to switch a direct current in a bidirectional manneracross output terminals of the grid-interactive inverter to provide analternating current to the utility grid, the controller is configured tomeasure the alternating output current provided to the utility gridusing the output current sensor, the controller is configured to performfrequency decomposition of the output current to determine the magnitudeof a plurality of unwanted current components; and the controller isconfigured to generate control signals that cause the switches in theDC-AC inverter stage to switch current in a bidirectional manner acrossthe output terminals in a way that the magnitude of each of theplurality of unwanted current components is subtracted from theresulting output current.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a system diagram of a power generation system in accordancewith an embodiment of the invention.

FIG. 2 is a circuit diagram of a grid-interactive inverter in accordancewith an embodiment of the invention,

FIG. 3 is a process diagram illustrating a harmonic cancellationfeedback loop in accordance with an embodiment of the invention.

FIG. 4 is a graph illustrating an output current waveform generatedusing harmonic cancellation in accordance with an embodiment of theinvention.

FIGS. 5a and 5b illustrating the bidirectional switching of currentthrough a primary coil of a transformer in a DC-DC conversion stage of agrid-interactive inverter.

FIG. 5c illustrates the ON and OFF states of MOSFETS in agrid-interactive inverter during the bidirectional switching of currentthrough a primary coil of a transistor.

FIGS. 6A and 6B are charts showing variation of efficiency of agrid-interactive inverter based upon the duty cycle and switchingfrequency of a DC-DC conversion stage at different output power levels.

FIG. 7 is a flow chart illustrating a process for changing the switchingfrequency and/or duty cycle of a DC-DC conversion stage in response tochanges in the output power generated by a grid-interactive inverterthat includes hysteresis in accordance with an embodiment of theinvention.

FIG. 8 is a state diagram illustrating a process for performing maximumpower point tracking in accordance with an embodiment of the invention.

FIG. 9 is a circuit diagram illustrating an inrush current limitingcircuit in accordance with an embodiment of the invention.

FIG. 10 is a circuit diagram illustrating a startup power check circuitin accordance with an embodiment of the invention.

FIG. 11a is a chart illustrating detection of an overcurrent event inaccordance with an embodiment of the invention.

FIG. 11b is a flow chart illustrating a process for performingovercurrent protection in accordance with an embodiment of theinvention.

FIG. 12 is a flow chart illustrating a process for modifying theoperation of a grid-interactive inverter as the output power of aphotovoltaic module fluctuates in accordance with embodiments of theinvention.

FIG. 13 illustrates symbol regions during a grid cycle.

DETAILED DESCRIPTION

Turning now to the drawings, various enhancements to grid-interactiveinverters in accordance with embodiments of the invention areillustrated. A variety of systems and methods are discussed that can beutilized in any of a variety of grid-interactive inverter topologies toimprove output current quality, power production and/or reliability.Grid-interactive inverters in accordance with embodiments of theinvention can include some or all of the enhancements depending upon thetopology of the grid-interactive inverter and/or the requirements of thespecific application. Indeed, many of the enhancements are appropriatein a variety of applications including for use in micro-inverters andstring inverters.

In a number of embodiments, the output current quality of agrid-interactive inverter is improved by configuring thegrid-interactive inverter to perform harmonic cancellation in the outputcurrent provided to the Grid. Grid-interactive inverters are typicallyexpected to supply “clean” power to the Grid. The degree to whichcurrent supplied by a grid-interactive inverter is clean can bequantified by a measure called total harmonic distortion, which is theratio of the power of the current in the fundamental (typically 50 or 60Hz) component divided by the sum of the power in the output current thatis due to other components up to the 40th harmonic of the fundamental.The grid is rarely a perfect sinusoid and there are non-linearities inthe output filters of most grid-interactive inverters. Therefore,driving the switches in a DC-AC inverter stage of a grid interactiveinverter with control signals that produce a perfect sinusoidal voltageacross the output filter of the inverter will not in general result in aperfect sinusoidal current being provided to the Grid from the output ofthe inverter. Accordingly, grid-interactive inverters in accordance withembodiments of the invention perform harmonic cancellation to reduce thepower in the output current due to components other than the fundamentalcomponent. In several embodiments, harmonic cancellation is achieved byperforming frequency decomposition of the observed output currentwaveform from the grid-interactive inverter. In several embodiments, thefrequency decomposition is performed using a Fast Fourier Transform(FFT). The magnitude of each of the components (other than thefundamental component) can be determined and the PWM control signalsmodified to subtract the unwanted components from the observed outputcurrent waveform. In this way, the total harmonic distortion of thecurrent supplied by a grid-interactive inverter can be significantlyreduced.

In many embodiments, the power output of a grid-interactive inverterthat includes a DC-DC conversion stage is increased using real timecontrol of the switching times in the DC-DC conversion stage. The powergenerated by a photovoltaic module can depend upon a variety of factorsincluding (but not limited to) the time of day, shade, temperature andthe point on the I-V curve of the photovoltaic module on which it isoperating. As is discussed further below, the output power and/orefficiency achieved by a grid-interactive inverter that includes a DC-DCconversion stage can be significantly increased by controlling theswitching times of the transistors within the DC-DC conversion stagebased upon the input power level, the output power level, and our theefficiency of the grid-interactive inverter. In several embodiments, acontroller within the grid-interactive inverter can select switchingtimes based upon a look up table. In a number of embodiments, acontroller within a grid-interactive inverter can select switching timesusing a real time optimization such as (but not limited to) a steepestdescent optimization. In this way, the overall power output of thegrid-interactive inverter under any given operating conditions can beincreased and/or the efficiency of the DC-DC conversion stage within thegrind-interactive inverter can be optimized.

In several embodiments, the power output of a grid-interactive inverterthat receives an input voltage from a photovoltaic module is increasedby controlling the power point of the photovoltaic module based upon themaximum power output of the grid-interactive inverter instead of byperforming maximum power point tracking. When the power output of aphotovoltaic module is diminished (e.g. at the beginning and end of eachday), then the operating power point of the photovoltaic module thatmaximizes the power output of the grid-interactive inverter may not bethe maximum power point of the photovoltaic module. When agrid-interactive inverter includes a DC-DC conversion stage, the outputDC voltage is a fixed ratio of the input DC voltage determined by thewindings of the transformer in the DC-DC conversion stage. At low outputpower, DC-AC inverter stages typically operate more efficiently at lowerinput DC voltages (and therefore low DC link voltages) due to lowerswitching losses. Therefore, operating a photovoltaic module at a lowervoltage than the maximum power point can increase the efficiency of agrid-interactive inverter, where the reduction in switching losses inthe inverter offsets the reduction in power output by the photovoltaicmodule. Accordingly, controlling the input voltage to thegrid-interactive inverter to maximize power output to the Grid inaccordance with embodiments of the invention can achieve increased poweroutput relative to performing maximum power point tracking.

In several embodiments, grid-interactive inverter reliability isincreased by utilizing circuits that limit inrush currents when the Gridinteractive inverter is first connected to the Grid, circuits thatperform startup power check to prevent the grid-interactive inverterfrom attempting to supply power to the Grid until sufficient power isavailable at the inverter's input, and/or a controller that monitors forovercurrent events and disconnects the output drive of thegrid-interactive invertor in response to an overcurrent event. In manyembodiments, the performance of grid-interactive inverters can bemonitored using power line communication between the grid-interactiveinverters and a gateway connected to an electrical panel. In a number ofembodiments, the Grid voltage is utilized by the grid-interactiveinverter for symbol time alignment and error correction codes are usedto correct packet errors resulting from impulse noise events in the Gridand inverter-generated noise.

Grid-interactive inverters and processes for improving output currentquality, power production and/or reliability in accordance withembodiments of the invention are discussed further below.

Power Generation Systems

Power generation systems in accordance with embodiments of the inventioninclude power generators, such as (but not limited to) photovoltaicmodules, that generate a DC voltage. The DC voltage can be converted toAC and supplied to the Grid via a grid-interactive inverter. Thegrid-interactive inverter can be a micro-inverter or a string inverter.In power generation systems that utilize micro-inverters, themicro-inverters can communicate with a gateway via the power line inaccordance with embodiments of the invention.

A power generation system incorporating micro-inverters in accordancewith embodiments of the invention is illustrated in FIG. 1. The powergeneration system 10 includes one or more photovoltaic modules 12 thatare connected via a grid-interactive inverter 14 to power lines 16,which connect to an electrical panel 18 via a junction box 20. Thegrid-interactive inverters are micro-inverters that convert DC to AC forsupply to the Grid 22. In a number of embodiments the AC is supplied tothe Grid via a meter 24 that can be used to measure the amount ofcurrent supplied to the Grid and/or consumed by other devices connectedto the electrical panel (not shown).

In many embodiments, the grid-interactive inverters 14 are configured tocommunicate with a gateway 26. The grid-interactive inverters 14 canprovide status information to the gateway 26 and the gateway can providecontrol information and/or additional information including (but notlimited to) firmware updates to the grid-interactive inverters. Systemsand methods for communicating via power lines in accordance withembodiments of the invention are discussed further below.

Although specific power generation systems are discussed above withrespect to FIG. 1, any of a variety of power generation systems inaccordance with embodiments of the invention can be utilized includingpower generation systems that incorporate different types of powergenerators. In addition, power generation systems in accordance withembodiments of the invention can incorporate grid-interactive invertersthat are string inverters. The manner in which grid-interactiveinverters can provide increased output current quality, power productionand/or reliability in a power supply system in accordance withembodiments of the invention is discussed further below.

Grid-Interactive Inverters

Grid-Interactive Inverters in accordance with embodiments of theinvention can be constructed using any conventional grid-interactiveinverter topology. Any of a variety of enhancements can be incorporatedwithin the topology in accordance with embodiments of the invention toincrease output current quality, power production and/or reliability.Specific enhancements that can be incorporated into a grid-interactiveinverter in accordance with embodiments of the invention are discussedfurther below with respect to the generalized multi-stagegrid-interactive inverter conceptually illustrated in FIG. 2. As canreadily be appreciated, the enhancements are not limited to use withgrid-interactive inverters similar to the inverter illustrated in FIG. 2and can be utilized in any of a variety of grid-interactive invertertopologies as appropriate to the requirements of a specific application.

A generalized circuit diagram of a multi-stage grid-interactive inverterin accordance with an embodiment of the invention is illustrated in FIG.2. The grid-interactive inverter 14 receives a DC input from aphotovoltaic module 12 via input terminals and provides an AC output toa set of power lines 16 via output terminals. In the illustratedembodiment, the grid-interactive inverter 14 includes a filter 30 thatis configured to reduce the impact of electromagnetic interference thatcan back-propagate from the switching DC-DC converter onto the wiresthat connect the inverter to the panel. Without such a filter,unacceptable levels of radiated emission on the DC lines may result. Thecurrent received from the photovoltaic module is provided to a DC-DCconversion stage 32 that provides current to a high voltage DC linkcapacitor 34 at a voltage in excess of the peak voltage of the Grid. Thehigh voltage DC link capacitor 34 provides current to a DC-AC inverterstage 36. The AC output of the DC-AC inverter stage 36 is filtered by apassive filter 38 to eliminate electromagnetic interference prior toproviding the AC to the Grid via the power lines 16. This low passfilter has a corner frequency that is several orders of magnitude higherthan the low frequency grid waveform. The AC switching produces atremendous amount of high frequency noise that would propagate onto thelocal grid if not rejected by this filter.

A controller 40 controls the switching in the DC-DC conversion stage 32and the DC-AC inverter stage 36. As discussed further below, thecontroller 40 can be configured to improve the quality of the outputcurrent by controlling the switching in the DC-AC inverter stage 36 toperform harmonic cancellation. The controller 40 can also be configuredto improve the power output of the grid-interactive inverter bycontrolling the switching in the DC-DC conversion stage to minimizepower losses based upon the power output of the photovoltaic module 12.In many embodiments, the controller 40 also increases the power outputof the grid-interactive inverter by controlling the output voltage ofthe photovoltaic module to maximize power output (as opposed toperforming maximum power point tracking). In a number of embodiments,the controller 40 can prevent damage to the components of thegrid-interactive inverter by monitoring for overcurrent events anddisconnecting the output drive of the DC-AC inverter from the Grid.

As can be readily appreciated, a variety of sensors are utilized inconjunction with the controller to perform the above functionality. Inseveral embodiments, a grid-interactive inverter 14 includes sensorsthat enable the controller to measure input and output current, measureinput and output voltage, and detect Grid voltage zero crossings. In anumber of embodiments, the grid-interactive inverter 14 also includes atemperature sensor. In other embodiments, any of a variety of sensorsappropriate to the requirements of a specific application can beutilized.

As noted above, grid-interactive inverters in accordance withembodiments of the invention can communicate with each other and/or agateway via the power lines to which the inverter is connected. In theillustrated embodiment, the grid-interactive inverter 14 includes apower line communication module 42 that handles the transmission ofsymbols via the power lines 16.

Although specific grid-interactive inverters are discussed above withrespect to FIG. 2, any of a variety of grid-interactive inverters can beutilized in accordance with embodiments of the invention. The specificcontrol processes and circuits that can be incorporated intogrid-interactive inverters in accordance with embodiments of theinvention to achieve increased output current quality, power productionand/or reliability in accordance with embodiments of the invention arediscussed further below.

Current Control and Harmonic Cancellation

Grid-interactive inverters in accordance with embodiments of theinvention can incorporate controllers that control the switching in aDC-AC inverter stage to perform harmonic cancellation. In a number ofembodiments, harmonic cancellation is achieved by observing the outputcurrent of the grid-interactive inverter and performing a frequencydecomposition of the observed current. The controller can then controlthe switching of the DC-AC inverter stage to subtract the magnitude ofthe unwanted components from the output current. In this way, thecontroller can reduce the total harmonic distortion in the output of thegrid-interactive inverter. The process of performing harmoniccancellation effectively involves creating a feedback loop thatsubtracts unwanted components from the output current.

In several embodiments, harmonic cancellation is performed using afeedback loop that performs a frequency decomposition of the presentlyobserved output current waveform:

${{Sobs}(t)} = {{\sum\limits_{k = 0}^{{Max} - 1}{\left( {\alpha_{k} + {j\beta_{k}}} \right){f_{k}(t)}}} + {\eta (t)}}$where f_(k)(t) = sin (2π(k + 1)f₀t); f₀ = 50  or  60  Hz

A vector that feeds back an iteratively accumulated superposition thatopposes the harmonic content in Sobs(t) is constructed below:

${{Sharmonic}(t)} = {{\sum\limits_{k = 0}^{{Max} - 1}{\left( {{\overset{˜}{\alpha}}_{k} + {j{\overset{˜}{\beta}}_{k}}} \right){f_{k}(t)}}} + {\eta (t)}}$where ${\overset{\sim}{\alpha}}_{0} = 1$

At each iterative time-step, the values of {tilde over (α)}_(k) and{tilde over (β)} _(k) can be updated to increment or decrement in adirection with the same sign to that of {tilde over (α)}_(k) and {tildeover (β)}_(k). Negative feedback is achieved by subtracting the arraybuilt from this superposition from the observed vector Sobs(t). Themagnitude of the harmonic correction array is also scaled by themagnitude of the observed array and the entire correction vector can bescaled by a constant that varies with the output power of the inverter:

PWM_(correction)(t) =Kp(power)[Sobs(t)−Sharmonic(t)*Max(Sobs(t))]

This array is passed through a low pass filter (implemented, forexample, as an exponential moving average (EMA)) to bandwidth limit therate of change and then added to what would otherwise be the defaultsinusoidal PWM control signal as follows:

PWMout(t)=[1+EMA(PWM_(correction)(t)]sin(2πƒ₀ t)

A harmonic correction current control loop that can be utilized in avariety of grid-interactive inverters in accordance with an embodimentof the invention is illustrated in FIG. 3. The observed current signalenters from the left and is operated on by a FFT block 52. The FFT blockprovides coefficients α_(k) and β_(k) which are then input to anaccumulator (54) to produce {tilde over (α)}_(k) and {tilde over(β)}_(k). {tilde over (α)}_(k) and {tilde over (β)}_(k) form the basisweights for the signal Sharmonic(t) generated by the signal generator56, which is multiplied (58) by the maximum observed value of the inputcurrent vector (60). The difference (62) between the resulting processedvector and the incoming current observation is then weighted (64) by aconstant Kp(power) that is a function of the output power of theinverter. The resulting error term is then low pass filtered (66) anddirectly applied to the PWM control module (68) in order to drive theswitching transistors of the DC-AC inverter in such a way as to reducethe power in the cancelled components of the observed output current.

Results associated with the current control PWM loop are shown in FIG.4. The output current 70 is shown as the lower amplitude, centeredcurve. The measured total harmonic distortion of the signal is less than2%. The grid voltage 72 is also shown (high amplitude centered curves).Inspection of the Grid voltage 72 reveals that its shape is notcompletely sinusoidal and exhibits distortion particularly near crestsand troughs of the wave-shape.

The chart in FIG. 4 also illustrates the voltage 74 across the highvoltage DC link capacitor of the grid-interactive inverter. The highvoltage DC link capacitor acts as an energy buffer. During periods inwhich peak output current is provided to the Grid, the chargeaccumulated on the capacitor drops and the voltage drop across thecapacitor is reduced. During periods in which the output current drops,charge accumulates on the capacitor. Two charging and discharging cyclesoccur with respect to the high voltage DC link capacitor for each cycleof the Grid. Due to the fact that energy buffering is performed at highvoltage (i.e. after the DC-DC conversion), the capacitance of the highvoltage DC link capacitor can be lower than the capacitance that wouldbe used to store an equivalent amount of energy at a lower voltage (e.g.where the energy buffering capacitor is located prior to the DC-DCconversion stage). Energy stored in a capacitor scales linearly withcapacitance, but quadratically with voltage. Therefore, a 10 timesincrease in voltage in the DC-DC conversion can result in a 100 timesdrop in the amount of capacitance used to buffer energy within thegrid-interactive inverter. Accordingly, highly reliable capacitors suchas (but not limited to) polypropylene metal film capacitors can beutilized to implement the high voltage DC link capacitor. Suchcapacitors are typically rated for longer useful lifespan than highercapacitance capacitors that utilize higher dielectric materials such asgel-based electrolytic capacitors.

In embodiments where a full-bridge output architecture is utilizedwithin a grid-interactive inverter, the inverter design allows‘four-quadrant’ operation of voltage and current waveforms. This meansthat the inverter can be configured to supply reactive current to theGrid in order to offset local reactive load demands. It also means thatit is possible to draw power from the Grid, for instance at times of daywhen energy is inexpensive, in order to rectify AC to DC for the purposeof charging a battery. Supplying reactive current to the Grid using thefeedback loop outlined above can simply be a matter of altering theobjective function of the harmonic current cancellation such that theresulting corrected waveshape meets the desired leading or lagging powerfactor. This is achieved by selecting a ratio of the fundamental (50 or60 Hz) real, I_(fund), and imaginary, Q_(fund), amplitudes such thatPF_(desired)=cos(Angle(I_(fund)/Q_(fund))).

Although specific harmonic cancellation processes and grid-interactiveinverters configured to perform harmonic cancellation are discussedabove with reference to FIGS. 3 and 4, any of a variety of harmoniccancellation processes can be implemented within a grid-interactiveinverter in accordance with an embodiment of the invention. Controllingswitching in a DC-DC conversion stage of a grid-interactive inverter inaccordance with embodiments of the invention is discussed further below.

Increasing Output Power by Controlling Switching of DC-DC Converters

DC-DC conversion stages utilized in many grid-interactive invertersinclude two half-bridge (high and low side) MOSFET devices joined by theprimary coil of a transformer. The secondary coil of the sametransformer can be rectified and the resulting higher voltage chargestored on a DC link capacitor. In many embodiments of the invention, acontroller within the grid-interactive inverter performs real-timeswitching optimization (frequency and duty cycle) of the DC-DC fullbridge switching transistors in order to increase the efficiency of theinverter. A variety of techniques can be utilized to determine thefrequency and duty cycle of the switching including (but not limited to)table based and steepest descent approaches.

The efficiency of a transformer in a DC-DC conversion stage is typicallya function of frequency at a given power level. Switching losses thatincrease with the frequency, however, can also impact the efficiency ofa DC-DC conversion stage. Accordingly, at any given operating power anoptimal combination of switching frequency and duty cycle exists. As isdiscussed further below, a controller can determine the output power ofa photovoltaic module and generate control signals that control theswitching frequency and/or duty cycle of the switching transistors toachieve an increase in efficiency.

The full-bridge switching of current through the primary coil of atransformer in a DC-DC conversion stage in order to lift panel voltage(typically between 20 and 40Vdc) to a higher voltage (e.g. between 340and 630 Vdc) is illustrated in FIGS. 5a and 5b . The periods of time inwhich each pair of transistors is ON and OFF are determined by a PWMsignal provided to the gates of the transistors. A PWM control signal isconceptually illustrated in FIG. 5c . The two key parameters in the PWMcontrol signal are Ton and Toff. The sum of these two parameters setsthe switching frequency and the ratio Ton/Ton+Toff defines the dutycycle. FIGS. 5a and 5b show the two on-state operating modes of the fullbridge. The time interval Ton.a indicates that current flows from theupper left switching device, through the primary coil of thetransformer, to the lower right switching device. The time intervalTon.b indicates that current flows from the upper right switching devicethrough the primary coil of the transformer to the lower left switchingdevice. Ton.a=Ton.b, the ‘a’ or ‘b’ designator simply indicates the pathof current flow.

In several embodiments, an improvement in overall inverter efficiencycan be achieved if Ton and Toff are varied depending on the power.Tables showing variation in efficiency of a grid-interactive inverterbased upon the duty cycle and switching frequency of the DC-DCconversion stage at different output power levels are illustrated inFIGS. 6a and 6b . For each power level, a matrix of values for Ton andToff was tested. Ton values were varied across 15 values from 6.8 to 14uSec and Toff varies across 8 values from 0.1 to 0.4 uSec. All 120pairwise combinations are tested for overall efficiency at the twodifferent output power levels. As can be readily appreciated by acomparison of FIGS. 6a and 6b , an optimal frequency and duty cycleexists. In addition, the optimal frequency and duty cycle varies withthe output power delivered to the Grid by the grid-interactive inverter.Accordingly, a controller can be configured to modify the switchingfrequency and duty cycle of the PWM control signal provided to thetransistors within a DC-DC conversion stage to increase efficiency basedupon the output power of the inverter. In several embodiments, thecontroller determines frequency and duty cycle based upon a look uptable. In many embodiments, the controller performs a steepest descentprocess to continuously locate the most efficient frequency and dutycycle for the DC-DC conversion stage.

A process for modifying the switching frequency and duty cycle of aDC-DC conversion stage of a grid-interactive inverter using a lookuptable in a manner that incorporates hysteresis in accordance withembodiments of the invention is illustrated in FIG. 7. The process 80commences by sampling (82) the power level. The sampled power level iscompared (84) to a threshold. In the illustrated embodiment, thethreshold has hysteresis so as to prevent a rapid set of changes in Ton,Toff if an inverter continued to operate near a switching boundary oftwo power levels. Specifically, a change occurs when the inverter outputpower exceeds a threshold by some margin in both the increasing anddecreasing power level directions in order for a change to occur. Once achange has been detected (84), then a look up table is used to find thebest Ton, Toff pairwise combination for the new level of interest andthe Ton, Toff pairwise combination is used to control (86) the switchingof the DC-DC conversion stage. As can be readily appreciated, anarbitrary number of power levels can be implemented.

Although the processes discussed above with respect to FIG. 7 use lookup tables to determine a Ton, Toff pairwise combination for a givenpower output level, a variety of real time optimization processes can beimplemented in accordance with embodiments of the invention to determinean appropriate Ton, Toff pairwise combination. In several embodiments, asteepest descent method is used to periodically update Ton, Toff. Inthis method, perturbation steps are taken in 4 directions, shorter andlonger Ton combined with shorter and longer Toff. The resulting pairwith the highest efficiency is then held. In many embodiments, thegrid-interactive inverter is able to measure its own efficiency usinginput and output voltage and current sensors. Additional perturbationsteps can be taken and the process continues indefinitely. Local minimaare avoided in the technique with a jump step that moves the Ton, Toffpairwise combination more than a single step away. As can be seen fromFIGS. 6a and 6b , local minima are not common and can easily be managedwith this technique. In other embodiments, any of a variety of processesfor selecting Ton, Toff pairwise combinations in real time to improvethe efficiency of a grid-interactive inverter can be utilized asappropriate to the requirements of specific applications in accordancewith embodiments of the invention.

Maximum Power Point Tracking

Photovoltaic modules provide different power in different points oftheir volt-ampere (I-V) characteristic. The point in the I-V curve whereoutput power is maximum is called the maximum power point (MPP).Micro-inverters are typically designed to assure that a photovoltaicmodule is operated near its MPP. This is accomplished with a specialcontrol circuit in called a MPP tracker (MPPT).

MPPTs in accordance with many embodiments of the invention set thephotovoltaic module operating voltage to maximize output power to theGrid. As is discussed further below, at low power the operating voltagethat produces the highest output power may not be the MPP. Thephotovoltaic module operating voltage set point can be set bycontrolling the conversion ratio between the DC link capacitor and theGrid. The grid voltage is not influenced by the inverter due to the lowimpedance nature of the Grid itself. Therefore, the conversion ratio,called Gain, between the high voltage DC link capacitor and the Gridserves to set the DC link voltage via the simple relation:

V _(DC_LINK)=√{square root over (2)}V _(Grid)/Gain

where Gain is a parameter that ranges from 0.55 to 1 (the lower bound isset by the maximum allowed DC link voltage, which is typically around620 Volts and is set based upon the requirements of a specificapplication).

Since the ratio of the photovoltaic module voltage to the DC link is setby the fixed turn ratio of the transformer in the DC-DC conversionstage, the Gain parameter is used to set the photovoltaic module voltagein the system during active export. For example, if the DC-DCtransformer has a ratio of 17:1, V_(grid)=240 Vrms, and Gain is set to0.8, then the DC photovoltaic module voltage will be set to √{squareroot over (2)}240/(0.8*17)=25 Volts. This single parameter, Gain, isused to set the photovoltaic module operating voltage such that thephotovoltaic module operates at the point where the product of themodule's voltage and current is maximized.

In order to continually track the maximum power operating point of thephotovoltaic module, the inverter perturbs the Gain parameter and thenwaits a period of time to observe if the exported power has increased ordecreased. If the exported power has increased, then the perturbationcontinues in the same direction. If the exported power has decreasedthen the direction is reversed. A key parameter to choose is theperturbation step size of the Gain parameter. In several embodiments ofthe invention, at least two step sizes are possible. One is relativelysmall and is used during a ‘slow’ tracking mode while this other isrelatively large and is used during a ‘fast’ acquisition mode.

In several embodiments, the MPPT switches from slow to fast mode when adeviation in output power above an adaptive threshold is exceeded. Thismay happen, for example, when a cloud crosses in front of the panelcausing total solar insolation to rapidly decline. Conversely, if whenin fast mode, only a small change in output power is observed for sometime, then the controller switches back to slow mode and again usesrelatively small steps of Gain to continue tracking the photovoltaicmodule's MPP. This hybrid approach between fast and slow withcorresponding coarse and fine panel voltage adjustments simultaneouslyprovides excellent dynamic tracking performance and high resolutionsteady state performance. This means that the MPPT increases thelikelihood that the inverter is producing as much power as possibleduring both static and dynamic insolation scenarios thereby maximizingMPPT efficiency (defined as the ratio of the integral of actual paneloutput to the integral of ideal panel output).

When photovoltaic module wattage is diminished, for instance at thebeginning and end of each day, then it may in fact be the case that thephotovoltaic module voltage operating point that maximizes the energyexported to the Grid by a grid-interactive inverter is not the MPP. Thisis because the grid-interactive inverter operates more efficiently atlower DC link voltages than at higher DC link voltages. This followsfrom the fact that less energy is lost when switching MOSFET devices inthe DC-AC inverter stage across lower voltages. Therefore, when exportpower is low, there can be a net advantage in total production tooperating away from the MPP by forcing the photovoltaic module voltageto be lower than the point that would otherwise be specified by the MPP.In several embodiments, the Gain is set away from the MPP at thebeginning and end of each day in order to maximize total production.

A process for performing maximum power tracking in accordance with anembodiment of the invention is illustrated in FIG. 8. The processincludes both slow (92) and fast (94) tracking states and describes therelative step size of the Gain parameter as being approximately 10×larger in the fast state (94) as compared to the slow state (92). Inother embodiments, the step sizes can be dimensioned in a mannerappropriate to the requirements of a specific application. In theillustrated embodiment, an exponential moving average (EMA) withexponential parameter 2⁻³ is used to construct an adaptive movingthreshold to gate a transition from slow to fast mode. A slower average,with EMA exponent 2⁻⁵ is used to set the adaptive level for transitionfrom fast to slow mode. In addition parameters K and L scale theaverages and a transition between states occurs based upon whether apower change, ΔP, between perturbation steps exceeds or is less than thescaled average (as appropriate). In other embodiments, any of a varietyof transition criterion can be utilized in accordance with therequirements of a specific application.

Finally, if the average power falls below a threshold, then the Gainparameter is set (96) to a constant and the MPPT is effective disabled.This may cause the panel to operate away from the MPP. However, aspreviously described, this choice yields higher total output power whenthe absolute power level has fallen below a threshold (e.g. 5 Watts, acase which can last for 20 or 30 minutes at the beginning and end ofeach day).

Although specific processes for controlling photovoltaic module voltageoperating points to maximize power output are discussed above withrespect to FIG. 8, any of a variety of processes that involve operatingaway from the MPP at lower power levels can be utilized as appropriateto the requirements of specific applications in accordance withembodiments of the invention.

Increasing Reliability

A key aspect of grid-interactive inverter design is the expectedoperational lifetime of the inverter. A variety of stresses can beplaced upon the components of a grid-interactive inverter during normaloperation that can significantly reduce the expected operationallifetime of the inverter. Various techniques for increasing thereliability of grid-interactive inverters in accordance with embodimentsof the invention are discussed further below including circuitsconfigured to limit in rush current when the grid-interactive inverteris first connected to the Grid, circuits that perform startup powercheck to prevent the grid-interactive inverter from attempting to supplypower to the Grid until sufficient power is available at the inverter'sinput, and/or use of a controller that monitors for overcurrent eventsand disconnects the output drive of the grid-interactive invertor inresponse to an overcurrent event.

In Rush Current Limiting Circuits

Grid-interactive inverters in accordance with many embodiments of theinvention store energy in a high voltage DC link capacitor havingcapacitance on the order of 10's to 100's of micro-Farads. Instantaneousapplication of grid voltage to the output of a DC-AC inverter stage(before the output drive is engaged) can cause the body diodes of theswitching MOSFETs in the DC-AC inverter stage to become forward biasedsuch that the voltage applied across the terminals of the link capacitorequals √{square root over (2)}Vgrid. With a 240 Vrms grid, for example,340 Vdc can be instantly applied across the terminals of the linkcapacitor. This can result in tremendous inrush current if allowed tooperate unabated. To mitigate this inrush, an inrush current limitingcircuit can be utilized.

An inrush current limiting circuit in accordance with an embodiment ofthe invention is illustrated in FIG. 9. The inrush current limitingcircuit 110 operates in a completely passive manner and requires noactive micro-processor control. This is important in as much as the ACconnection to grid may be made prior to the DC connection to a panel(used to power the microprocessor) or may be made at night. The on-stateresistance of the MOSFET power transistor 112 is an order of magnitudesmaller than that of the negative thermal coefficient (NTC) devices thatare typically used to limit inrush current. Similarly, the initialoff-state resistance of the overall inrush limiter can be set severalorders of magnitude higher than that of the initial off-state resistanceof an NTC device. This means that both the initial inrush limit and thefinal active resistance are dramatically better than that of an NTCdevice.

In the illustrated embodiment, at the time of initial connection, therectified Grid voltage is applied across points Vdd,Vss and the currentthat flows through the DC link capacitor is limited by the relativelyhigh resistance value of 113. Meanwhile, the capacitor 114 is slowcharged through resistors 115 while the gate of transistor 112 isprotected with diodes 116. Component values are scaled such that therate of charge of capacitor 114 slower than the rate of charge of the DClink capacitors. This ensures that the link capacitors are sufficientcharged to prevent inrush current above a given amperage thresholdbefore transistor 112 enters a fully saturated cony state. This activityhappens only when the inverter goes from a state of being disconnectedto connected to the Grid. The circuit is fully autonomous and improvesthe reliability of the inverter by protecting components from inrushcurrents during connection events throughout the lifetime of the device.

Although a specific inrush current limiting circuit is illustrated inFIG. 9, any of a variety of current inrush limiting circuits appropriateto the requirements of specific applications can be utilized inaccordance with embodiments of the invention. Processes for furtherincreasing reliability of grid-interactive inverters by using startuppower checks in accordance with embodiments of the invention arediscussed further below.

Startup Power Check

Grid-interactive inverters including (but not limited to)micro-inverters have active components that are powered via energysupplied from the photovoltaic panel rather than the Grid. This meansthere is a causality issue associated with starting export at thebeginning of a day some period after sunrise. The inverter, for example,draws a minimum of W watts when it connects to the Grid. When the panelis not able to supply W watts and an attempt to connect to the Grid ismade, then an immediate brown-out event will likely occur in which themain supply voltage from the panel drops below the necessary voltage toprovide minimum expected voltage regulation to various circuits withinthe grid-interactive inverter. When this occurs the inverter immediatelydisconnects from the Grid due to sensing a panel voltage low event. Theconnection instance of the inverter to the Grid (switching the AC drivefrom a passive to active state) invariably results in some amount ofcurrent rush until all internal loops have stabilized. This rushing ACcurrent is not catastrophic, but it places additional stress oncomponents that should be avoided if possible. Hence it is desirable tohave only a single grid connection event per day. In many embodiments, apower check circuit is utilized to determine whether the photovoltaicmodule is generating sufficient power to support connection of thegrid-interactive inverter to the Grid. The power check circuit is acircuit incorporated within the grid-interactive inverter that enablesthe inverter to measure the power being generated by a photovoltaicmodule and make a determination concerning whether there is sufficientpower to start providing power to the Grid.

A power check circuit in accordance with an embodiment of the inventionis illustrated in FIG. 10. The power check circuit 140 switches on priorto the decision to engage the AC and DC drives of the grid-interactiveinverter. The power check circuit operates by connecting (though a powerMOSFET 142) a fixed resistance 144 in parallel across the supplyterminals of the panel. The resistor 144 is scaled such thatR_(pow_check)=V²min/P_(min). In this equation, V_(min) is the minimumoperational panel voltage and P_(min) is the minimum inverterconsumption when grid interactive under export of 0 watts of power.Connecting the resistor 144 and then checking that the voltage on thepanel remains above V_(min) provides an indication that enough power isbeing generated by the panel for a successful grid-connection event tooccur without occurrence of a brown-out. If power check passes, then theAC and DC drives are enabled sequentially one after the other. Next,maximum power point tracking begins. If at any point an AC Over Currentevent or the Panel voltage drifts too low, then the AC and DC drives areenabled and the power check procedure is re-initiated.

Although a specific power check circuit is illustrated in FIG. 10, anyof a variety of circuits can be incorporated within a grid-interactiveinverter to check the output power generated by a photovoltaic module inaccordance with embodiments of the invention. Processes for increasingthe reliability of grid-interactive inverters by performing real-timeovercurrent protection in accordance with embodiments of the inventionare discussed further below.

Real-Time Overcurrent Protection

Grid-intertie involves real-time maintenance of a nearly constantimpedance between the high voltage DC link capacitor and the presentgrid voltage at all phases of any given line cycle. The output AC driveswitching PWM control signal generated by the controller within thegrid-interactive inverter sets this impedance and controls the rate ofcurrent flow from the high voltage DC link capacitor to the relativelylower voltage Grid. The Grid, however, is a very low impedance sourceitself, and if for any reason a mismatch occurs between the inverteroutput and the Grid voltage, then very large currents can rush into orout of the inverter. Reasons for these mismatches includeGrid-instabilities such as instantaneous voltage or phase changes. Anovercurrent event can be defined as an event in which the sensed ACoutput current exceeds a predetermined threshold, |A_(th)|. Overcurrentevents in accordance with this definition are illustrated in FIG. 11 a.

To protect the inverter output-stage from overcurrent events, the outputdrive of the grid-interactive inverter can be immediately disconnectedby simultaneously setting all MOSFET gates to a low state within theDC-AC inverter stage. A process for disconnecting the output drive of agrid-interactive inverter in response to over current events inaccordance with an embodiment of the invention is illustrated in FIG.11b . The process 150 is continuously operating as a background processwhen the controller of a grid-interactive inverter is active. A currentsample is obtained 152, a determination is made concerning whether thesample has a value in excess of the predetermined threshold, |A_(th)|.In the event that the current exceeds the predetermined threshold, thena count is incremented 154. Any combination of more than K over-currentevents causes the output drive to immediately disconnect 156. Adisconnect of the AC drive means that all output MOSFET gates are set toa low state simultaneously. This sends any residual current through thebody diodes of each MOSFET and initiates a passive connection to theGrid in which the output drive simply rectifies the Grid voltage to thehigh voltage DC link capacitor. In this mode no current flows from theGrid to the inverter's high voltage DC link capacitor once the DC linkvoltage is equal to or greater than the peak AC voltage. Once currentceases to flow, the inverter is protected from any further grid anomalythat may occur.

Although specific processes for providing overcurrent protection arediscussed above with reference to FIGS. 11a and 11b , any of a varietyof processes can be utilized to sample current and disconnect the outputdrive of a grid-interactive inverter in accordance with embodiments ofthe invention. A description of typical operation flow in which variousprocesses and circuits discussed above can be used in combination toimprove the performance and reliability of the grid-interactive inverteris described below.

Daytime Flow

Due to variation in solar insolation throughout the day-to-day operationof a grid-interactive inverter, the grid-interactive inverter willexperience periods in which a photovoltaic module provides negligiblepower, provides lower power sufficient to start the grid-interactiveinverter, and provides high power. Various processes are described abovefor achieving additional power production during the low power operationof a grid-interactive inverter and for preventing harm to thegrid-interactive inverter as it transitions from ON to OFF states.

A flow chart illustrating various processes performed during theday-to-day operation of a grid-interactive inverter in accordance withembodiments of the invention is illustrated in FIG. 12. The process 160commences when the photovoltaic module produces sufficient power thatthe power check is passed (162) and so the grid-interactive inverter cancommence supplying power to the Grid without risk of brown out. At whichpoint, a controller within the grid-interactive inverter commencessending control signals to the switches within the DC-AC inverter toenable (164) the AC drive and current control functionality of thegrid-interactive inverter. Due to the low power produced during thephotovoltaic module during the initial start up phase, the Gain of thegrid-interactive inverter is set to a constant. The controller can thenstart providing (166) control signals to start driving the DC-DCconversion stage and adjusting the frequency and duty cycle of the DC-DCconversion stage switching to increase the output power of the inverter.As the power output by the photovoltaic module increases, the MPPT isenabled (168) and the Gain of the grid-interactive inverter is optimizedfor power export (i.e. no longer constant). As power drops, the MPPT isdisabled (170) and the Gain is fixed to a constant until such time asthe power output of the photovoltaic necessitates shutting down thegrid-interactive inverter.

Throughout the operation of the process shown in FIG. 12, a backgroundprocess is performed to determine (172) whether an over current eventhas occurred and/or (174) whether the voltage of the photovoltaic modulehas dropped to a value that is too low to continue providing power tothe Grid. In the event that either event occurs, the controller ceasesdriving the DC-DC conversion stage and the DC-AC inverter stage. Inaddition, the power check circuit can be activated.

Although specific processes for managing the exporting of power to agrid using a grid-interactive inverter during the day-to-day operationof a photovoltaic module are discussed above with reference to FIG. 12,any of a variety and/or combination of processes appropriate to therequirements of a specific application can be utilized to manage theoperation of a grid-interactive inverter in accordance with anembodiment of the invention.

Power Line Communication

In several embodiments, grid-interactive inverters include thecapability of communicating via the power lines to which the invertersare connected. Communicating over the Grid using power lines as a mediuminvolves careful consideration for noise while at the same timenecessitating a simple implementation to allow for low cost. Somefeatures of the Grid as a communication medium can assist in reducingcost. In several embodiments, the Grid is used for symbol timealignment. The grid phase is known to all inverters by way of a zerocrossing detection and phase lock tracking. Recovered grid frequency andphase can be divided into an equal number of segments at each inverter.These segments can be used to define symbol time boundaries as subsetsof each line cycle frequency and phase.

In a number of embodiments, the grid-interactive inverter utilizes amulti-rate on-off keying power line communication physical layer andmedia access control protocol. In several embodiments, the physicallayer of the protocol provides a series of different rates that areachieved by increasing or decreasing the signal constellation density oneach line cycle. Forward error correction can also be integrated. Inother embodiments, any of a variety of communication protocols can beutilized in accordance with embodiments of the invention. The manner inwhich forward error correction can be integrated to reduce the number ofpacket errors that occur when communicating via power lines inaccordance with embodiments of the invention is discussed further below.

Use of Error Correction Codes

Impulse noise events in the Grid and inverter-generated self-noiseinvariably lead to symbol flips that can lead to packet errors. Errorcorrection code can be utilized to increase link reliability. In severalembodiments, a (24, 12) Golay error correcting code is utilized thatconveys 12 bits of information for each 24 total transmitted bits andcan correct up to 3 possible errors. In a number of embodiments, length24 symbol Golay codewords are transmitted over a span of {1, 2, 3, 4, 6,12, 24} line cycles. This corresponds to {24, 12, 8, 6, 4, 2, 1}transmission regions per line cycle. Note that the pairwise product ofthe corresponding elements of each of the above arrays always equals 24(the number of symbols per Golay codeword) and that both arrays includethe set of integer divisors of 24. The effective user data rate (noparity) for each of these divisors is {720, 360, 240, 180, 120, 60, 30}bits per second. The seven separate transmit symbol constellationscorresponding to the transmission rates above are illustrated in FIG.13. In the figure the relative phase of a line cycle from 0 to 1 (0 to2π) is displayed on the x axis. Then for each of the seven rates perline cycle, the center position of each possible symbol is displayed onthe y axis.

This adaptive rate approach provides up to 10 log 10(720/30)=13.8 dB ofsignal to noise ratio gain from the highest to lowest rate. Thecombination of grid aligned symbol synchronization, Golay forward errorcorrection, and adaptive rate modulation form a powerful yet lowcomplexity implementation to achieve robust communication over the powerline medium.

Although specific error correction methods are discussed above withrespect to Golay error correction code, any of a variety of errorcorrection processes appropriate to the requirements of specificapplications can be utilized in accordance with embodiments of theinvention. Furthermore, the communication protocol need not adapt andcan simply involve transmitting at a fixed rate using grid alignedsymbol synchronization.

While the above description contains many specific embodiments of theinvention, these should not be construed as limitations on the scope ofthe invention, but rather as an example of one embodiment thereof.Accordingly, the scope of the invention should be determined not by theembodiments illustrated, but by the appended claims and theirequivalents.

What is claimed:
 1. A grid-interactive inverter configured to receivedirect current and to provide alternating current to a grid, comprising:input terminals configured to receive a direct current; output terminalsconfigured to provide an alternating output current to the grid; acontroller; at least one sensor capable of measuring alternating outputcurrent provided to the grid; a DC-AC inverter comprising a plurality ofswitches controlled by control signals generated by the controller;wherein the controller is capable of generating the control signals thatcause the plurality of the switches in the DC-AC inverter to switch adirect current in a bidirectional manner across output terminals of thegrid-interactive inverter to provide an alternating output current tothe grid; wherein the controller is capable of dynamically generatingthe control signals that cause the plurality of the switches in theDC-AC inverter to switch current in a bidirectional manner across theoutput terminals in response to the measured alternating output currentto provide reactive current to the grid; wherein the DC-AC inverter isan H-bridge inverter comprising four MOSFETs, each of the four MOSFETshaving a body diode; and wherein the four MOSFETs are configured toreceive PWM control signals from the controller, where the PWM controlsignals configure the four MOSFETs to switch current in a bidirectionalmanner through an output filter connected to the output terminals of thegrid-interactive inverter.
 2. The grid-interactive inverter of claim 1,wherein the controller is configured to perform frequency decompositionof the measured alternating output current by performing a Fast FourierTransform of the measured output current.
 3. The grid-interactiveinverter of claim 1, further comprising: a DC-DC converter comprising aplurality of switches connected to a primary coil of a transformer, anda full bridge rectifier connected to an output of a secondary coil ofthe transformer, where the plurality of switches in the DC-DC converterare controlled by the control signals generated by the controller; and aDC link capacitor configured to link the DC-DC converter and the DC-ACinverter; wherein the controller is configured to generate controlsignals that cause the plurality of the switches in the DC-DC converterto switch the direct current received via the input terminals in abidirectional manner across the primary coil of the transformer; whereinthe transformer is wound so that the output voltage of the secondarycoil is greater than the input voltage of the primary coil; and whereinthe DC link capacity or provides a direct current to the DC-AC inverter.4. The grid-interactive inverter of claim 3, wherein the DC linkcapacitor is a polypropylene metal film capacitor.
 5. Thegrid-interactive inverter of claim 3, further comprising: an outputvoltage sensor; wherein the controller is capable of making a powermeasurement of the alternating output current provided to the grid usingthe output current sensor and the output voltage sensor; and wherein thecontroller is configured to select a new switching frequency and dutycycle for the plurality of the switches in the DC-DC converter basedupon at least the measured power of the alternating current provided tothe grid.
 6. The grid interactive inverter of claim 5, furthercomprising: an input current sensor; and an input voltage sensor;wherein the controller is capable of making a power measurement of thedirect current received via the input terminals of the grid-interactiveinverter; and wherein the controller is further configured to select thenew switching frequency and duty cycle for the plurality of the switchesin the DC-DC converter based upon the ratio of the measured power of thedirect current received via the input terminals to the measured power ofthe alternating output current provided to the grid.
 7. Thegrid-interactive inverter of claim 6, wherein the controller is furtherconfigured to select the new switching frequency and duty cycle for theplurality of the switches of the DC-DC converter by perturbing at leastone of the frequency and duty cycle of the plurality of the switches inthe DC-DC converter and making a power measurement of a resultingalternating output current to determine whether an increase in the ratioof the measured power of the direct current received via the inputterminals to the measured power of the alternating output currentprovided to the grid results.
 8. The grid-interactive inverter of claim5, wherein the controller is further configured to select the newswitching frequency and duty cycle for the plurality of the switches ofthe DC-DC converter based upon the measured power of the alternatingoutput current provided to the grid using a look up table.
 9. Thegrid-interactive inverter of claim 3, wherein the controller isconfigured to perform a maximum power point tracker process.
 10. Thegrid-interactive inverter of claim 9, wherein the controller isconfigured to disable the maximum power point tracker process and tocontrol the voltage on the DC link capacitor to establish apredetermined voltage for the direct current input.
 11. Thegrid-interactive inverter of claim 3, further comprising an autonomousgrid inrush current limiter circuit comprising: at least one resistorconnected in series with the DC link capacitor; a switch in parallelwith the at least one resistor connected in series with the DC linkcapacitor; and a capacitor charging circuit comprising a capacitor andat least one resistor connected in series with the capacitor, where thecapacitor charging circuit is connected to the output terminals of thegrid-interactive inverter and configured to charge the capacitor in thecapacitor charging circuit using current drawn from the grid; whereinthe time constant of the capacitor and the at least one resistor in thecharging circuit is longer than the time constant of the DC linkcapacitor and the at least one resistor in series with DC linkcapacitor; and wherein the ON state of the switch connected in parallelwith the at least one resistor connected in series with the DC linkcapacitor is controlled by the voltage level of the capacitor in thecapacitor charging circuit such that the current flows through theswitch when the voltage level of the capacitor exceeds a predeterminedthreshold.
 12. The grid-interactive inverter of claim 11, wherein theswitch in parallel with the at least one resistor connected in serieswith the DC link capacitor is a low ON state resistance MOSFET switch.13. The grid-interactive inverter of claim 1, further comprising: astartup power check circuit connected to the input terminals of thegrid-interactive converter and comprising at least one resistorconnected in series with a switch between the input terminals; and aninput voltage sensor configured to measure the voltage across the inputterminals; wherein the controller is configured to determine a minimuminput power that can be supplied by a photovoltaic module connected tothe input terminals by measuring a voltage across the input terminals ofthe grid-interactive inverter when the switch is configured to permitcurrent to flow through the at least one resistor connected in seriesbetween the input terminals.
 14. The grid-interactive inverter of claim1, wherein the controller is configured to sample an output currentsensor and turn off the plurality of the switches in the DC-AC inverterin response to a predetermined number of the samples within a grid cyclehaving magnitudes exceeding an overcurrent threshold.
 15. The gridinteractive inverter of claim 1, further comprising: a communicationmodule that utilizes the grid cycle to perform symbol time alignment;wherein the communication module is configured to transmit data usingON/OFF keying; wherein the communication module is configured to encodetransmitted data using an error correction code; and wherein thecommunication module is configured to adapt the number of symboltransmissions per grid cycle.
 16. The grid interactive inverter of claim15, wherein the error correction code is a Golay code.
 17. The gridinteractive inverter of claim 1, wherein: the at least one sensorcomprises an output current sensor; the controller is capable ofmeasuring alternating output current provided to the grid using theoutput current sensor; the controller comprises a current control loopcapable of performing frequency decomposition of the alternating outputcurrent in order to generate feedback to the controller; and thecontroller is capable of using the feedback to generate the controlsignals that cause the plurality of the switches in the DC-AC inverterto switch current in a manner that results in the alternating outputcurrent waveform meeting a desired leading or lagging power factor. 18.The grid interactive inverter of claim 1, wherein: the controller iscapable of generating the control signals that cause the plurality ofthe switches in the DC-AC inverter to switch current bidirectionallyacross the output terminals to achieve a desired power factor; and thecontroller is capable of dynamically generating the control signals tooffset local reactive load demands by changing the desired power factorin response to the measurement of the alternating output current that isprovided to the grid.
 19. The grid interactive inverter of claim 18,wherein the desired power factor (PF_(desired)) is determined by theratio of the fundamental real (I_(fund)) and imaginary (Q_(fund))amplitudes of the alternating output current such that:${PF_{desired}} = {\cos \; {\left( {{Angle}\left( \frac{I_{fund}}{Q_{fund}} \right)} \right).}}$20. The grid interactive inverter of claim 1, wherein the controller iscapable of dynamically generating the control signals that cause theplurality of the switches in the DC-AC inverter to achieve four-quadrantoperation of the alternating output current and voltage waveforms.